company ’s desire to minimize its environmental footprint and
to build on its commitment to sustainability through many dif-
ferent facets of the business.
These green aspects include product design, where Fred-
man works with customers to downsize material thickness
and package dimensions therefore maximizing the overall
cost reduction for the customer and Fredman itself; in manu-
facturing, as the firm utilizes a regenerative thermal oxidizer
to destroy volatile organic compounds (VOCs) by blasting
exhaust with extremely hot air; in processing, by recapturing
and recycling unconsumed solvents, reducing cooling water
usage through recycling and reconditioning, as well as recy-
cling industrial paper, cardboard, and spent oil; in packaging
by shipping finished products on recycled pallets and reused
roll cores; and in energy reduction, by upgrading to vari-
able speed motors over single speed motors on equipment
exhaust systems, replacing production and office lighting
with high efficiency lighting and using motion detectors and
setback thermostats to help conserve energy.
While these initiatives may seem somewhat time and cost
intensive, the reality is that by spending more capital on these
technologies now, Fredman will see significant cost savings in
the future.
“ We value this opportunity to work with the DNR,” said Tim
Fredman, president and owner, Fredman Bag. “ The ability to
partner with the DNR is greatly appreciated and we value the
added help and resources a collaborative relationship brings.
Our results show that being environmentally conscious does
not have to be a burden to a business. These efforts make
sense, not only from an environmental impact standpoint, but
because they are also generally advantageous from both a
safety and cost savings perspective.”
In May 2012, Fredman, in an effort to increase total em-
ployee involvement in the recycling efforts, added an audit
program into its quarterly bonus program. The program veri-
fies recyclable materials are in the recycling waste streams
and not in the landfill waste streams.
From a process waste standpoint, the majority of the firm’s
plastic scrap stream has always been captured and recycled.
But, it keeps working to include additional items to be recycled.
In the last year, Fredman added plastic spools received
from zipper suppliers and several additional categories
of poly material. This increased the amount of material
recycled by 4 percent. But even with these items added into
the calculations, the
company has reduced
the total amount of
scrap produced and
sent to the recycler by
67 percent in the last
six years. Furthermore,
when looking at the
landfill shipments, the
total material sent to
the landfill has been
reduced by 40 percent in the same six-year period.
Fredman Bag also has big plans for the future. This
includes converting industrial cleaning agents to environmen-
tally friendly water based systems, replacing the facility ’s hot
water heater with a higher efficiency unit, continuing to im-
prove lighting efficiency, recycling additional waste products,
and continuing to significantly reduce solvent usage. With the
help of the Green Tier, Fredman Bag will be able to continue
to reduce its environmental footprint. And, with Fredman
added to the list of the firms within the Green Tier, Wisconsin
businesses will be able to continue to develop new and inno-
vative ways to continue environmental conservation.
As a unique program in the nation, Green Tier provides a
range of tools to create a powerful, sustainable
force for economic growth and environmental
health. Green Tier participation has grown
throughout Wisconsin’s business community in
recent years, as more companies have found
business value through greater environmental
performance.
For more information on Green Tier and Fred-
man Bag’s involvement, visit DNR’s Green Tier
web page at: http://dnr.wi.gov/topic/GreenTier/
Participants/FredmanBag.html n
The latest data shows FBC has reduced its VOCs by over 40 percent in the last 5 years.
www.flexomag.com
summer 2012
Sustainable FLEXO
9
Fredman Bag has witnessed
sustainaBility in...
Product design; work with customers to downsize mate-
rial thickness and package dimensions.
Manufacturing; utilize regenerative thermal oxidizer to
destroy VOCs.
Processing; recapture and recycle unconsumed
solvents. Reduce cooling water usage by recycling and
reconditioning. Recycle industrial paper, cardboard,
and spent oil.
Packaging; ship product on recycled pallets and re-use
roll cores.
Energy reduction; upgrade to variable speed motors
versus single speed motors on equipment exhaust sys-
tems. Replace production and office lighting with high
efficiency lighting. Utilize motion detectors and setback
thermostats to help conserve energy.
30%
35%
40%
45%
50%
55%
60%
65%
70%
2004
2005
2006
2007
2008
2009
2010
2011
%MaxPermit
Year
Fredman Bag VOC Trend
Photo of the firm’s
original plant location